Edge insulation structure for electrical cable

ABSTRACT

An edge insulated electrical cable includes an electrical cable and an edge insulation structure applied to the electrical cable at the location. An apparatus for applying edge coating to a film is also disclosed.

BACKGROUND

Electrical cables for transmission of electrical signals are known. Onecommon type of electrical cable is a coaxial cable. Coaxial cablesgenerally include an electrically conductive wire surrounded by aninsulator. The wire and insulator are typically surrounded by a shield,and the wire, insulator, and shield are surrounded by a jacket. Anothercommon type of electrical cable is a shielded electrical cablecomprising one or more insulated signal conductors surrounded by ashielding layer formed, for example, by a metal foil. To facilitateelectrical connection of the shielding layer, a further un-insulatedconductor is sometimes provided between the shielding layer and theinsulation of the signal conductor or conductors.

SUMMARY

In one embodiment, an edge insulated electrical cable includes anelectrical cable having a conductive material disposed near a locationat a longitudinal edge of the electrical cable and susceptible to makingelectrical contact at the location and an insulating material bonded tothe electrical cable at the location.

In another embodiment, an electrical cable includes a conductorextending lengthwise along the cable and a reservoir extendinglengthwise along the cable at a first lateral location in the cable,wherein the reservoir contains a dielectric material adapted to betransferred to a different second lateral location in the cable.

In yet another embodiment, an edge insulated electrical cable includesan electrical cable having a conductive material disposed near alongitudinal edge and susceptible to making electrical contact at theedge, wherein the cable is folded along the length of the cable, thefold defining a first portion facing a second portion, the secondportion comprising the longitudinal edge of the cable, and a bondingmaterial bonding the second portion to the first portion along thelength of the cable.

In one embodiment, an edge insulated electrical cable includes anelectrical cable having a first layer and a second layer, the secondlayer having a conductive material disposed near a longitudinal edge ofthe second layer and susceptible to making electrical contact at theedge, wherein the second layer is folded along the length of the cabletoward the first layer, the fold defining a first portion of the secondlayer facing a second portion of the second layer, the second portion ofthe second layer comprising the longitudinal edge of the second layer,and a bonding material bonding the second portion of the second layer tothe first portion of the second layer along the length of the cable.

In one embodiment, a method of applying an insulating material to alongitudinal edge of an electrical cable includes the step of:dispensing the insulating material to at least one of a top and bottomsurfaces of the electrical cable proximate and along the longitudinaledge; allowing the insulating material to flow over the longitudinaledge; and curing the insulating material.

In another embodiment, an apparatus for film edge coating includes a dieassembly configured to dispense a material through a die tip, and anedge of a film positioned proximate the die tip, wherein the dieassembly dispenses the material to at least one of a top and bottomsurfaces of the film proximate and along the edge of the film, thedispensed material forming a coated region on the film, the coatedregion being limited to near the edge of the film.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated in and constitute a part ofthis specification and, together with the description, explain theadvantages and principles of the invention. In the drawings,

FIG. 1 illustrates an exemplary embodiment of an edge insulatedelectrical cable;

FIG. 2 is a cross-sectional view of an exemplary embodiment of an edgeinsulation structure;

FIGS. 3A-3D illustrate a number of exemplary embodiments of edge beads;

FIG. 4 is a cross-sectional view of an exemplary embodiment of anelectrical cable having a reservoir extending lengthwise along thecable;

FIG. 5 illustrates an exemplary embodiment of an edge bead formed by thedielectric material disposed in the reservoir;

FIGS. 6A-6E illustrate a number of exemplary embodiments of edgeinsulation structure in edge films;

FIGS. 7A-7P illustrate a number of exemplary embodiments of edgeinsulation structures formed by folding;

FIG. 8 illustrates an exemplary embodiment of a die assembly;

FIG. 9A illustrates a perspective view of an embodiment of a die tip;

FIG. 9B illustrates a side view of the embodiment of the die assemblyillustrated in FIG. 9A;

FIG. 9C illustrates a close-up view of an edge insulation structurecovering an edge of a film;

FIG. 10A illustrates a perspective view of another embodiment of a dietip;

FIG. 10B illustrates a side view of the embodiment of the die tipillustrated in FIG. 10A;

FIGS. 11A and 11B illustrates a close-up perspective view of twoembodiments of a die tip;

FIG. 12A illustrates a die lip open view of an embodiment of a die tip;

FIG. 12B illustrates a side view of the embodiment of the die tipillustrated in FIG. 12A;

FIG. 13A illustrates a die lip open view of another embodiment of a dietip;

FIG. 13B illustrates a side view of the embodiment of the die tipillustrated in FIG. 13A;

FIG. 14A illustrates a die lip open view of yet another embodiment of adie tip; and

FIG. 14B illustrates a side view of the embodiment of the die tipillustrated in FIG. 14A.

DETAILED DESCRIPTION

Some types of electrical cable are not insulated along the longitudinaledges of the cables. In some cases, an electrical cable may include aconductive material disposed near a longitudinal edge of the cable. Insome cases, the conductive material may be included to provideshielding. As the number and speed of interconnected devices increases,electrical cables that carry signals between such devices need to besmaller and capable of carrying higher speed signals withoutunacceptable interference or crosstalk. Shielding is used in someelectrical cables to reduce interactions between signals carried byneighboring conductors. Many of the cables described herein have agenerally flat configuration, and include conductor sets that extendalong the length of the cable, as well as electrical shielding filmsdisposed on opposite sides of the cable. Pinched portions of theshielding films between adjacent conductor sets help to electricallyisolate the conductor sets from each other. However, such conductivematerial disposed near the edge, for example, shielding films, issusceptible to making electrical contact at the edge and causing anelectrical short. Specifically, the cable edge can cause shorting whenit is in electrical contact with a conductive surface with a voltagedifferent from ground. It is therefore of interest to create anon-conductive edge on the cable. This disclosure is directed to variousedge insulation structures applied to a cable edge to reduce thepossibility of electrical shorts. The edge insulation structure can begenerated when the cable is constructed, or at a later step. Besidespreventing electrical shorts, the edge insulation structures may alsoprevent moisture from penetrating the cable. This disclosure is alsodirected to apparatus and methods for applying material to an edge of afilm. The same apparatus and methods can be used to create an edgeinsulation structure.

In some implementations, electrical cables are trimmed to suitable widthafter they are made. The trimming may cause exposure of conductivematerial at some locations along the edge of the cable. In thissituation, it is beneficial to apply insulation structures at thoselocations. In some cases, it is not necessary to apply insulationstructures along the entire edge of an electrical cable. For example, insuch cases, insulation structures may be applied to a number oflocations on the edge of the cable such that the possibility ofelectrical shorts is reduced.

FIG. 1 illustrates an exemplary embodiment of an edge insulatedelectrical cable 100. The edge insulated electrical cable 100 includesan electrical cable 110 and an edge insulation structure 120 along thelengthwise edge of the cable 110. In some implementations, the edgeinsulation structure 120 can include an insulating material. Theinsulating material may be, for example, any types of dielectricmaterials. The dielectric material can be, for example, a UV curablematerial, a thermoplastic material, or the like.

In some embodiments, the edge insulation structure can be constructed toan essentially cylindrical shape, or referred to as edge bead herein. Insome embodiments, the edge bead can be constructed by one of any classesof dielectric material that is flexible under certain condition, suchthat the dielectric material can be applied to the cable edge. Forinstance, the edge bead can be constructed by pressure sensitiveadhesives, hot melt materials, thermoset materials, and curablematerials. The pressure sensitive adhesives include those based onsilicone polymers, acrylate polymers, natural rubber polymers, andsynthetic rubber polymers. They may be tackified, crosslinked, and/orfilled with various materials to provide desired properties. Hot meltmaterials become tacky and adhere well to substrates when they areheated above a specified temperature and/or pressure; when the adhesivecools down, its cohesive strength increases while retaining a good bondto the substrate. Examples of types of hot melt materials include, butare not limited to, polyamides, polyurethanes, copolymers of ethyleneand vinyl acetate, and olefinic polymers modified with more polarspecies such as maleic anhydride. Thermoset materials are materials thatcan create an intimate contact with a substrate either at roomtemperature or with the application of heat and/or pressure. Withheating, a chemical reaction occurs in the thermoset to provide longterm cohesive strength at ambient, subambient, and elevatedtemperatures. Examples of thermoset materials include epoxies,silicones, and polyesters, and polyurethanes. Curable materials caninclude thermosets, but are differentiated here in that they can cure atroom temperature, either with or without the addition of externalchemical species or energy. Examples include two-part epoxies andpolyesters, one-part moisture cure silicones and polyurethanes, andadhesives utilizing actinic radiation to cure such as UV, visible light,or electron beam energy.

In some embodiments, the edge insulation structure can be constructed byone or more layers of film covering the edge of the cable, referred toas edge film herein. In some implementations, the edge film can includea layer of polymeric material, including but not limited to polyester,polyimide, polyamide-imide, polytetrafluoroethylene, polypropylene,polyethylene, polyphenylene sulfide, polyethylene naphthalate,polycarbonate, silicone rubber, ethylene propylene diene rubber,polyurethane, acrylates, silicones, natural rubber, epoxies, andsynthetic rubber adhesive. In some other implementations, the edge filmcan also include one or more additives and/or fillers to provideproperties suitable for the intended application. The additives andfillers can be, for example, flame retardants, UV stabilizers, thermalstabilizers, anti-oxidants, lubricants, color pigments, or the like.

In some embodiments, the edge insulation structure 120 can include botha conductive material and an insulating material. The conductivematerial can be bonded to the electrical cable 110 while the insulatingmaterial can be applied over the conductive material. The insulationstructure 120 may use material that is part of the cable's construction,for example, adhesive material that is used in the cable. In anexemplary embodiment, the electrical cable 110 includes one or moreconductor sets 104, where each conductor set 104 includes one or moreinsulated conductors along the length of the electrical cable. In someembodiments, the edge insulation structure 120 may bond to a portion ofthe edge of the electrical cable 110, but not the entire edge, such thatthe possibility of electrical short is reduced.

The electrical cable 110 may include conductive material disposed near alocation on a longitudinal edge of the cable that is susceptible toelectrical contact at the location on the cable. For example, theconductive material can be shielding films 108 disposed across the cablepotentially making electrical contact at or near the edge. In someembodiments, the electrical cable 110 includes a plurality of conductorsets 104 spaced apart from each other along all or a portion of a width,w, of the cable 110 and extend along a length, L, of the cable 110. Thecable 110 may be arranged generally in a planar configuration asillustrated in FIG. 1 or may be folded at one or more places along itslength into a folded configuration. In some implementations, some partsof cable 110 may be arranged in a planar configuration and other partsof the cable may be folded. In some configurations, at least one of theconductor sets 104 of the cable 110 includes two insulated conductors106 extending along a length, L, of cable 110. The two insulatedconductors 106 of the conductor sets 104 may be arranged substantiallyparallel along all or a portion of the length, L, of the cable 110.Insulated conductors 106 may include insulated signal wires, insulatedpower wires, or insulated ground wires. Two shielding films 108 aredisposed on opposite sides of the cable 110.

The first and second shielding films 108 are arranged so that, intransverse cross section, cable 110 includes cover regions 114 andpinched regions 118. In the cover regions 114 of the cable 110, coverportions 107 of the first and second shielding films 108 in transversecross section substantially surround each conductor set 104. Forexample, cover portions of the shielding films may collectivelyencompass at least 75%, or at least 80%, 85%, or 90% of the perimeter ofany given conductor set. Pinched portions 109 of the first and secondshielding films form the pinched regions 118 of cable 110 on each sideof each conductor set 104. In the pinched regions 118 of the cable 110,one or both of the shielding films 108 are deflected, bringing thepinched portions 109 of the shielding films 108 into closer proximity.In some configurations, as illustrated in FIG. 1, both of the shieldingfilms 108 are deflected in the pinched regions 118 to bring the pinchedportions 109 into closer proximity. In some configurations, one of theshielding films may remain relatively flat in the pinched regions 118when the cable is in a planar or unfolded configuration, and the othershielding film on the opposite side of the cable may be deflected tobring the pinched portions of the shielding film into closer proximity.

The cable 110 may also include an adhesive layer 140 disposed betweenshielding films 108 at least between the pinched portions 109. Theadhesive layer 140 bonds the pinched portions 109 of the shielding films108 to each other in the pinched regions 118 of the cable 110. Theadhesive layer 140 may or may not be present in the cover region 114 ofthe cable 110.

In some cases, conductor sets 104 have a substantiallycurvilinearly-shaped envelope or perimeter in transverse cross-section,and shielding films 108 are disposed around conductor sets 104 such asto substantially conform to and maintain the cross-sectional shape alongat least part of, and preferably along substantially all of, the lengthL of the cable 110. Maintaining the cross-sectional shape maintains theelectrical characteristics of conductor sets 104 as intended in thedesign of conductor sets 104. This is an advantage over someconventional shielded electrical cables where disposing a conductiveshield around a conductor set changes the cross-sectional shape of theconductor set.

Although in the embodiment illustrated in FIG. 1, each conductor set 104has exactly two insulated conductors 106, in other embodiments, some orall of the conductor sets may include only one insulated conductor, ormay include more than two insulated conductors 106. For example, analternative shielded electrical cable similar in design to that of FIG.1 may include one conductor set that has eight insulated conductors 106,or eight conductor sets each having only one insulated conductor 106.This flexibility in arrangements of conductor sets and insulatedconductors allows the disclosed shielded electrical cables to beconfigured in ways that are suitable for a wide variety of intendedapplications. For example, the conductor sets and insulated conductorsmay be configured to form: a multiple twinaxial cable, i.e., multipleconductor sets each having two insulated conductors; a multiple coaxialcable, i.e., multiple conductor sets each having only one insulatedconductor; or combinations thereof. In some embodiments, a conductor setmay further include a conductive shield (not shown) disposed around theone or more insulated conductors, and an insulative jacket (not shown)disposed around the conductive shield.

In the embodiment illustrated in FIG. 1, shielded electrical cable 110further includes optional ground conductors 112. Ground conductors 112may include ground wires or drain wires. Ground conductors 112 can bespaced apart from and extend in substantially the same direction asinsulated conductors 106. Shielding films 108 can be disposed aroundground conductors 112. The adhesive layer 140 may bond shielding films108 to each other in the pinched portions 109 on both sides of groundconductors 112. Ground conductors 112 may electrically contact at leastone of the shielding films 108. Some exemplary electrical cableconstructions are discussed in detail in U.S. Patent Application No.61/348,800, entitled “Shielded Electrical Cable” and U.S. PatentApplication No. 61/378,856, entitled “High Density Shielded ElectricalCable and Other Shielded Cables, Systems and Methods,” which areincorporated herein by reference in entirety.

FIG. 2 is a cross-sectional view of an exemplary embodiment of an edgeinsulation structure 200. In an exemplary embodiment, the edgeinsulation structure 200 includes an insulating material 250. Insulatingmaterial 250 can be any types of material providing insulation andcapable of being bonded to a part of a cable close to the edge. Forexample, insulating material can form an edge insulation structure withbead-like shape. The insulating material 250 is bonded to the edge ofthe cable, where the cable includes layers of, for example, dielectricfilms 210, adhesive layers 220, shielding films 230 (i.e. metal), anddielectric layers 240 (i.e. hot melt adhesive).

The shielding films 230 can have a variety of configurations and be madein a variety of ways. In some cases, one or more shielding films mayinclude a conductive layer and a non-conductive polymeric layer. Theconductive layer may include any suitable conductive material, includingbut not limited to copper, silver, aluminum, gold, and alloys thereof.The non-conductive polymeric layer may include any suitable polymericmaterial, including but not limited to polyester, polyimide,polyamide-imide, polytetrafluoroethylene, polypropylene, polyethylene,polyphenylene sulfide, polyethylene naphthalate, polycarbonate, siliconerubber, ethylene propylene diene rubber, polyurethane, acrylates,silicones, natural rubber, epoxies, and synthetic rubber adhesive. Thenon-conductive polymeric layer may include one or more additives and/orfillers to provide properties suitable for the intended application. Insome cases, at least one of the shielding films may include a laminatingadhesive layer disposed between the conductive layer and thenon-conductive polymeric layer. For shielding films that have aconductive layer disposed on a non-conductive layer, or that otherwisehave one major exterior surface that is electrically conductive and anopposite major exterior surface that is substantially non-conductive,the shielding film may be incorporated into the shielded cable inseveral different orientations as desired. In some cases, for example,the conductive surface may face the conductor sets of insulated wiresand ground wires, and in some cases the non-conductive surface may facethose components. In cases where two shielding films are used onopposite sides of the cable, the films may be oriented such that theirconductive surfaces face each other and each face the conductor sets andground wires, or they may be oriented such that their non-conductivesurfaces face each other and each face the conductor sets and groundwires, or they may be oriented such that the conductive surface of oneshielding film faces the conductor sets and ground wires, while thenon-conductive surface of the other shielding film faces conductor setsand ground wires from the other side of the cable.

In some cases, at least one of the shielding films may be or include astand-alone conductive film, such as a compliant or flexible metal foil.The construction of the shielding films may be selected based on anumber of design parameters suitable for the intended application, suchas, e.g., flexibility, electrical performance, and configuration of theshielded electrical cable (such as, e.g., presence and location ofground conductors). In some cases, the shielding films may have anintegrally formed construction. In some cases, the shielding films mayhave a thickness in the range of 0.01 mm to 0.05 mm. The shielding filmsdesirably provide isolation, shielding, and precise spacing between theconductor sets, and allow for a more automated and lower cost cablemanufacturing process. In addition, the shielding films prevent aphenomenon known as “signal suck-out” or resonance, whereby high signalattenuation occurs at a particular frequency range. This phenomenontypically occurs in conventional shielded electrical cables where aconductive shield is wrapped around a conductor set.

As discussed elsewhere herein, adhesive material may be used in thecable construction to bond one or two shielding films to one, some, orall of the conductor sets at cover regions of the cable, and/or adhesivematerial may be used to bond two shielding films together at pinchedregions of the cable. A layer of adhesive material may be disposed on atleast one shielding film, and in cases where two shielding films areused on opposite sides of the cable, a layer of adhesive material may bedisposed on both shielding films. In the latter cases, the adhesive usedon one shielding film is preferably the same as, but may if desired bedifferent from, the adhesive used on the other shielding film. A givenadhesive layer may include an electrically insulative adhesive, and mayprovide an insulative bond between two shielding films. Furthermore, agiven adhesive layer may provide an insulative bond between at least oneof shielding films and insulated conductors of one, some, or all of theconductor sets, and between at least one of shielding films and one,some, or all of the ground conductors (if any). Alternatively, a givenadhesive layer may include an electrically conductive adhesive, and mayprovide a conductive bond between two shielding films. Furthermore, agiven adhesive layer may provide a conductive bond between at least oneof shielding films and one, some, or all of the ground conductors (ifany). Suitable conductive adhesives include conductive particles toprovide the flow of electrical current. The conductive particles can beany of the types of particles currently used, such as spheres, flakes,rods, cubes, amorphous, or other particle shapes. They may be solid orsubstantially solid particles such as carbon black, carbon fibers,nickel spheres, nickel coated copper spheres, metal-coated oxides,metal-coated polymer fibers, or other similar conductive particles.These conductive particles can be made from electrically insulatingmaterials that are plated or coated with a conductive material such assilver, aluminum, nickel, or indium tin-oxide. The metal-coatedinsulating material can be substantially hollow particles such as hollowglass spheres, or may comprise solid materials such as glass beads ormetal oxides. The conductive particles may be on the order of severaltens of microns to nanometer sized materials such as carbon nanotubes.Suitable conductive adhesives may also include a conductive polymericmatrix.

When used in a given cable construction, an adhesive layer is preferablysubstantially conformable in shape relative to other elements of thecable, and conformable with regard to bending motions of the cable. Insome cases, a given adhesive layer may be substantially continuous,e.g., extending along substantially the entire length and width of agiven major surface of a given shielding film. In some cases, theadhesive layer may include be substantially discontinuous. For example,the adhesive layer may be present only in some portions along the lengthor width of a given shielding film. A discontinuous adhesive layer mayfor example include a plurality of longitudinal adhesive stripes thatare disposed, e.g., between the pinched portions of the shielding filmson both sides of each conductor set and between the shielding filmsbeside the ground conductors (if any). A given adhesive material may beor include at least one of a pressure sensitive adhesive, a hot meltadhesive, a thermoset adhesive, and a curable adhesive. An adhesivelayer may be configured to provide a bond between shielding films thatis substantially stronger than a bond between one or more insulatedconductor and the shielding films. This may be achieved, e.g., byappropriate selection of the adhesive formulation. An advantage of thisadhesive configuration is to allow the shielding films to be readilystrippable from the insulation of insulated conductors. In other cases,an adhesive layer may be configured to provide a bond between shieldingfilms and a bond between one or more insulated conductor and theshielding films that are substantially equally strong. An advantage ofthis adhesive configuration is that the insulated conductors areanchored between the shielding films. When a shielded electrical cablehaving this construction is bent, this allows for little relativemovement and therefore reduces the likelihood of buckling of theshielding films. Suitable bond strengths may be chosen based on theintended application. In some cases, a conformable adhesive layer may beused that has a thickness of less than about 0.13 mm. In exemplaryembodiments, the adhesive layer has a thickness of less than about 0.05mm.

A given adhesive layer may conform to achieve desired mechanical andelectrical performance characteristics of the shielded electrical cable.For example, the adhesive layer may conform to be thinner between theshielding films in areas between conductor sets, which increases atleast the lateral flexibility of the shielded cable. This may allow theshielded cable to be placed more easily into a curvilinear outer jacket.In some cases, an adhesive layer may conform to be thicker in areasimmediately adjacent the conductor sets and substantially conform to theconductor sets. This may increase the mechanical strength and enableforming a curvilinear shape of shielding films in these areas, which mayincrease the durability of the shielded cable, for example, duringflexing of the cable. In addition, this may help to maintain theposition and spacing of the insulated conductors relative to theshielding films along the length of the shielded cable, which may resultin more uniform impedance and superior signal integrity of the shieldedcable.

A given adhesive layer may conform to effectively be partially orcompletely removed between the shielding films in areas betweenconductor sets, e.g., in pinched regions of the cable. As a result, theshielding films may electrically contact each other in these areas,which may increase the electrical performance of the cable. In somecases, an adhesive layer may conform to effectively be partially orcompletely removed between at least one of the shielding films and theground conductors. As a result, the ground conductors may electricallycontact at least one of shielding films in these areas, which mayincrease the electrical performance of the cable. Even in cases where athin layer of adhesive remains between at least one of shielding filmsand a given ground conductor, asperities on the ground conductor maybreak through the thin adhesive layer to establish electrical contact asintended.

The edge insulation structure may take various forms, for example, edgebeads, insulating films, and edge folding. FIGS. 3A-3E illustratecross-section views of a number of exemplary embodiments of edge beadsaccording to aspects of the present disclosure, including an electricalcable 300 and an edge bead 310. The cable 300 can include a plurality oflayers. In some cases, one of the plurality of layers can be conductive.As used herein, an edge bead refers to an edge insulation structure witha lump at the edge. In some configurations, the lump at the edge may beessentially round at cross-section. In some configurations, the edgebead can include a portion bonded to the top and/or bottom surface ofthe cable to provide better support. The edge bead 310 includes one ormore edge bead materials. The edge bead materials typically includedielectric material that is not rigid under certain conditions such thatthe dielectric material can be applied to the edge of the cable 300conforming to the shape of the edge. In some embodiments, the edge beadmaterials include a thermoplastic or a curable compound, for example, aUV curable, 3-beam, or air curable compounds. In some cases, the edgebead materials can include adhesive material such that a dielectricmaterial to the electrical cable 300 via the adhesive material. In someother cases, the edge bead material can include a coating material toprovide protection to the insulation structure. In some implementations,a dielectric material is applied to the edge of the electrical cable ina liquid form (i.e., melt, solution, etc.). How to construct an edgebead is discussed further below.

FIG. 3A illustrates an exemplary embodiment of edge bead 310 coveringonly the edge of a cable 300. The edge bead 310 may have a cross-sectionshape of, for example, a half-circle or a portion of circle, coveringthe edge. In some cases, stronger bonding of the edge bead 310 to thecable 300 can be obtained when the material applied to at least one ofthe top surface and bottom surface of the cable and the edge. FIG. 3Billustrates an exemplary embodiment of an edge bead 310 covering boththe edge and a portion of top and bottom surface of the cable 300. Incross sectional view, the edge bead may be generally round. FIG. 3Cillustrates another exemplary embodiment of an edge bead 310 that coversthe edge and both portions of the top surface and bottom surface of thecable near the edge. In this embodiment, the edge bead 310 can have awidth, which covers portions of the top surface and bottom surface,greater than its thickness. FIG. 3D illustrates a further exemplaryembodiment of an edge bead 310 that covers more area on one surface thanarea on the opposing surface of the cable 300.

In some embodiments, the edge bead 310 can be formed, at least in part,by a dielectric material that is used in the electrical cable 300. Asillustrated in FIG. 3D, the cable 300 can have a plurality of layersincluding a dielectric layer 320. The dielectric layer 320 can containdielectric material 325. The dielectric material 325 may be, forexample, thermoplastic or hot melt material, that is used to bond theshielding films (i.e. 230 in FIG. 2). In a particular embodiment, thedielectric material 325 may be adapted to transfer to another locationin the cable when it is subjected to condition changes. For example, thedielectric material 325 may move to another location when it is underpressure. In another example, the dielectric material 325 may becomeflowable when it is heated. In some cases, the edge insulation structuremay be formed by extruding the dielectric material 325 from near theedge to outside the edge. In some configurations, the dielectricmaterial 325 is any class of adhesive materials that can be bonded tothe electrical cable 300. The edge bead 310 can be formed by thedielectric material 325. In some other configurations, the edge portionof the electrical cable 300 is coated with adhesive material before thedielectric material 325 is extruded from the cable 300. In yet otherconfigurations, after the dielectric material 325 is applied to the edgeof the cable 300, another material can be applied on top of thedielectric material 325 to provide support and/or protection, forexample, to cover the dielectric material 325.

In some embodiments, an electrical cable may include a reservoir or apocket extending lengthwise along the electrical cable at a firstlateral location, as illustrated in FIG. 4. The reservoir may beconfigured to contain a dielectric material adapted to be transferred toa second lateral location in the cable that is different from the firstlateral location in the cable. An edge insulation structure can beformed by the dielectric material being transferred to the outer edge ofthe cable. FIG. 4 is a cross-sectional view of an exemplary embodimentof an electrical cable 400 having a reservoir 420 extending lengthwisealong the cable. The reservoir 420 may have a larger volume than itsadjacent areas 430 along the widthwise in the cable. The reservoir 420may store dielectric material 425 adapted to be transferred to a secondlocation of the cable. In some configurations, the reservoir 420 cancontain dielectric material 425 that is flowable under certaincondition. For example, the dielectric material 425 can become flowableafter heat is applied.

In some embodiments, the dielectric material can be transferred to asecond lateral location when the reservoir is extruded, pressed,squeezed, or by other mechanical approaches. In some cases, thedielectric material can be transferred to a second lateral location whenthe reservoir is heated. The dielectric material in the reservoir canflow to the edge of the electrical cable to form an edge bead. FIG. 5illustrates an exemplary embodiment of an edge bead 510 formed by thedielectric material 525 disposed in a reservoir 520 of an electricalcable 500. In some configurations, at least a portion of thelongitudinal edge of the electrical cable 500 is coated with a layer ofadhesive before the dielectric material 525 is extruded from the cable500, for example, from the reservoir 420 as illustrated in FIG. 4.

FIGS. 6A-6E illustrate a number of exemplary embodiments of edgeinsulation structure in edge films. In some embodiments, these edgefilms are typically applied to regions near a longitudinal edge of anelectrical cable. The edge films can be of any suitable polymericmaterial, including but not limited to polyester, polyimide,polyamide-imide, polytetrafluoroethylene, polypropylene, polyethylene,polyphenylene sulfide, polyethylene naphthalate, polycarbonate, siliconerubber, ethylene propylene diene rubber, polyurethane, acrylates,silicones, natural rubber, epoxies, and synthetic rubber adhesive.Additionally, the edge films can include one or more additives and/orfillers to provide properties suitable for the intended application.

FIGS. 6A and 6B illustrate an embodiment of an edge film 610 foldedaround an electrical cable 600. In some other embodiments, theelectrical cable 600 can have a plurality of layers including aconductive layer disposed at the edge of the electrical cable 600. Suchconductive layer may increase possibility of electrical contact at theedge of the cable 600. The edge film 610 can include one or more layersof material. In an exemplary embodiment, the edge film 610 may include alayer of adhesive material 620 and a layer for backing 630. In anotherembodiment, the edge film 610 may include a single layer of materialthat is bonded to the cable 600. In yet another exemplary embodiment,the edge film 610 may include a conductive layer and a dielectric layer,where the conductive layer can provide shielding and the dielectriclayer can reduce the possibility of electrical shorts. In further otherexemplary embodiments, the edge film 610 can include a plurality oflayers, for example, a conductive layer, a layer of dielectric material,and a layer of backing.

FIGS. 6C and 6D illustrate another embodiment of an edge insulatedelectrical cable 650 with edge film. An edge insulation structure isformed by an upper edge film 660 and a lower edge film 670 bondedtogether by, for example, any mechanical, adhesive, or chemical means.In an exemplary embodiment, the edge films 660 and 670 may include alayer of a layer for dielectric material 690. Optionally, at least oneof the edge films 660 and 670 include a layer of adhesive material 680.In some cases, both the edge films 660 and 670 include a layer ofadhesive material 680. In such configurations, the edge films 660 and670 may be bonded together by adhesive layers 680. In some other cases,only one of the edge films includes the adhesive layer 680. For example,the upper edge film 660 includes the adhesive layer 680 and the loweredge film 670 does not include an adhesive layer. The upper edge filmand a lower edge film 670 can be bonded by the adhesive layer 680. Inanother embodiment, the edge film 610 may include a single layer ofdielectric material 690 that can be bonded to the cable 600. The singlelayer of material can be, for example, a layer of curable compound. Inyet other cases, the edge films 660 and 670 can include a plurality oflayers, for example, a conductive layer, a layer of dielectric material,and a layer of backing.

FIG. 6E illustrates another exemplary embodiment of edge insulated cable650 with edge films constructed similar to the embodiment illustrated inFIG. 6D. In an exemplary embodiment, at least one of the edge films 660and 670 may cover the entire cable surface of the cable 650 and forminsulation structures along the lengthwise at both side of the cable.

FIGS. 7A-7P illustrate a number of exemplary embodiment of edgeinsulation structure formed by folding. An electrical cable 700 has aconductive material disposed at a location near a longitudinal edge andis susceptible to making electrical contact at the edge. In someembodiments, the electrical cable 700 is folded along the length of thecable. The fold of the cable defines a first portion of the cable and asecond portion of the cable, where the second portion of the cableincludes the longitudinal edge of the cable. An edge insulationstructure is formed by a bonding material bonding the second portion tothe first portion along the length of the cable.

FIG. 7A illustrates an exemplary embodiment of an edge insulationstructure 710 constructed by folding. In this embodiment, an electricalcable 700 is folded along the lengthwise line 715. The electrical cable700 typically has a dielectric material layer as the outmost layers onboth the top and bottom surfaces. The cable 700 has two portionsseparated by the line 715: a first portion 705 and a second portion 707.The second portion 707 includes the longitudinal edge of the cable 700.The second portion 707 can be folded over the first portion 705 andbonded to the first portion 705 by any bonding means, for example, byadhesive materials, hot melt materials, or the like. Thus, the edgeinsulation structure 710 is formed by a dielectric material layer coversthe edge of the cable 700.

FIG. 7B illustrates another exemplary embodiment of an edge insulationstructure 710 constructed by folding. In this embodiment, an electricalcable 700 is folded along the lengthwise line 715. The cable 700 has twoportions separated by the line 715—a first portion 705 and a secondportion 707. The second portion 707 includes the longitudinal edge ofthe cable 700. The second portion 707 can be folded on top of the firstportion 705 and bonded to the first portion 705 by any bonding means,for example, by adhesive materials, hot melt materials, or the like. Inan exemplary embodiment, the edge of the cable 700 can be furthercovered by an edge bead 720. The edge bead 720 can be constructed by oneor more edge bead materials described above. Thus, the edge insulationstructure 710 is formed.

FIG. 7C illustrates yet another exemplary embodiment of an edgeinsulation structure 710 constructed by folding. In this embodiment, anelectrical cable 700 is folded along the lengthwise line 715. The folddefines a first portion 705 and a second portion 707. The second portion707 includes the longitudinal edge of the cable 700. The second portion707 can be folded on top of the first portion 705 and bonded to thefirst portion 705 by any bonding means, for example, by adhesivematerials, hot melt materials, or the like. The edge of the cable 700can be further covered by an edge bead 720. The edge bead 720 caninclude dielectric material 730. The dielectric material 730 may be usedin the construction of the cable 700. The dielectric material 730 may beextruded from cable to cover the edge of the cable. Thus, the edgeinsulation structure 710 is formed.

In one embodiment, an electrical cable 700 is folded at a reservoir 740,as illustrated in FIGS. 7D and 7E. In this embodiment, the electricalcable 700 is separated (i.e., cut, etc.) at the reservoir 740. In anexemplary embodiment, the electrical cable 700 can be separated along aline 750 crossing the reservoir 740. The reservoir 740 includes twoportions of films along the cutting line 750: a bottom film 760 and atop film 765. The bottom film 760 typically includes an insulating layer770 as the outer layer. Next, the bottom film 760 of the reservoir 740can wrap around the longitudinal edge of the cable 700. As illustratedin FIG. 7E, after the bottom film 760 wrap around the longitudinal edgeof the cable 700, the insulating layer 770 becomes the outer layercovering the longitudinal edge of the cable 700 thus provides insulationto the edge. In some embodiments, the bottom film 760 comprises aconductive material layer 780 inside the insulating layer 770. In suchimplementations, the conductive material layer 780 can provide shieldingand the insulating layer 770 remained as an outmost layer to provideinsulation when the bottom film 760 is folded. The bottom film 760 maybe bonded to the top surface 790 of the cable 700 by adhesive or otherbonding materials to form an edge insulation structure 710. In somecases, the adhesive or bonding materials can be disposed inside thereservoir 740. In some implementations, a smaller cavity 795 containingresidue material of the original reservoir 740 can be formed by thefolding. In some other implementations, the folded structure can be flatwith no cavity. In some implementations, the reservoir 740 can includean insulating layer 770. The cable 700 can be cut at the reservoir alongthe length of the cable, where the cut exposes a longitudinal edge ofthe cable. A portion of the insulation layer 770 of the reservoirremained with the cable can wrap around the longitudinal edge of thecable 700 to form an edge insulation structure.

FIGS. 7F and 7G illustrate some other embodiments of an edge insulationstructure 710 formed by folding. Referring to FIG. 7F, an electricalcable 700 is folded and the fold defines a first portion 705 and asecond portion 707. The second portion 707 includes the longitudinaledge of the cable 700. In some cases, the cable 700 can includeconductive materials disposed at a location near the edge that issusceptible to make electrical contact at the location. The secondportion 707 can be folded along the length of the cable toward the firstportion 705 and bonded to the first portion 705 by any bonding means,for example, by adhesive materials, hot melt materials, or the like. Thesecond portion 707 may have a first layer 708 and a second layer 709. Insome implementations, the second layer 709 is cut or trimmed to beshorter than the first layer 708. The second layer 709 is covered by thefirst layer 708 to form the edge insulation structure 710.

FIG. 7G illustrates a similar implementation to the one illustrated inFIG. 7F, where an edge insulation structure 710 is formed by a secondportion 707 folded over a first portion 705 then a first layer 708covering a second layer 709 in the second portion 707. In someembodiments, an edge bead 720 can be applied to the edge of the firstlayer 708 to complete the edge insulation structure 710. The edge bead720 can be constructed by one or more edge bead materials describedabove. In some implementations, the edge bead 720 can be constructed bymaterials that are used in the cable construction.

FIGS. 7H-7P illustrate a number of embodiments of edge insulationstructure 710 formed by folding a certain layer of an electrical cable700. In some embodiments, an electrical cable 700 has a first layer 708and a second layer 709, where the second layer has a conductive materialdisposed near a longitudinal edge of the second layer and is susceptibleto making electrical contact at the edge. The second layer 709 of thecable is folded along the length of the cable toward the first layer708, and the fold defining a first portion 711 of the second layer and asecond portion 712 of the second layer comprising the longitudinal edgeof the second layer. An edge insulation structure is formed by a bondingmaterial bonding the second portion 712 of the second layer to thesecond portion 712 of the second layer along the length of the cable.

FIGS. 7H and 7I illustrate an exemplary embodiment of edge insulationstructure formed by folding. Referring to FIG. 7H, an electrical cable700 include a first layer 708 and a second layer 709. The second layer709 may have a conductive material disposed near a longitudinal edge ofthe second layer and be susceptible to making electrical contact at theedge. Referring to FIG. 7I, the second layer 709 is folded along thelength of the cable toward the first layer 708, and the fold defines afirst portion 711 of the second layer 709 and a second portion 712 ofthe second layer 709. The second portion 712 may include thelongitudinal edge of the second layer 709. An edge insulation structure710 is formed by bonding the second portion 712 of the second layer tothe first portion 711 of the second layer along the length of the cableby a bonding material.

FIG. 7J illustrates a similar embodiment to the one illustrated in FIG.7I. In some embodiments, in addition to the folding illustrated in FIG.7I, an edge bead 720 can be applied to the first layer 708 and the firstportion 711 of the second layer 709 to complete the edge insulationstructure 710. The edge bead 720 can be constructed by one or more edgebead materials described above. In some implementations, the edge bead720 can be constructed by materials that are used in the cableconstruction.

FIG. 7K illustrates one embodiment of an edge insulation structure 710formed by folding An electrical cable 700 includes a first layer 708 anda second layer 709. The first layer 708 is trimmed to have a shorterlength. The second layer 709 is folded along the length of the cabletoward the first layer 708, and the fold defines a first portion 711 ofthe second layer 709 and a second portion 712 of the second layer 709.The second portion 712 of the second layer may include the longitudinaledge of the second layer 709. The second portion 712 of the second layeris further folded along the length of the cable toward the first layer708, and the fold defines a third portion 713 and a fourth portion 714of the second layer. An edge insulation structure 710 is formed by abonding material bonding the fourth portion 714 of the second layer tothe third portion 713 of the second layer along the length of the cable.

FIG. 7L illustrates a similar embodiment to the one illustrated in FIG.7K. In some embodiments, in addition to the folding illustrated in FIG.7K, an edge bead 720 can be applied to the first layer 708 and thefourth portion 714 of the second layer 709 to complete the edgeinsulation structure 710. The edge bead 720 can be constructed by one ormore edge bead materials described above. In some implementations, theedge bead 720 can be formed by materials that are used in the cableconstruction.

FIGS. 7M and 7N illustrate an embodiment of constructing an edgeinsulation structure by folding. Referring to FIG. 7M, an electricalcable 700 can include a first layer 708 and a second layer 709. Theelectrical cable 700 typically has a dielectric outmost layer. Both thefirst layer 708 and the second layer 709 can be folded toward the otherlayer respectively. Referring to FIG. 7N, the second layer 709 can befolded along the length of the cable toward the first layer 708, and thefold defining a first portion 711 of the second layer 709 and a secondportion 712 of the second layer 709. The second portion 712 of thesecond layer 709 may include the longitudinal edge of the second layer709. The second portion 712 of the second layer can be bonded to thefirst portion 711 of the second layer along the length of the cable by abonding material. The first layer 708 can be folded along the length ofthe cable toward the second layer 709, and the fold defining a firstportion 717 of the first layer 708 and a second portion 716 of the firstlayer 708. The second portion 716 of the first layer 708 may include thelongitudinal edge of the first layer 708. The second portion 716 of thefirst layer 708 can be bonded to the first portion 717 of the firstlayer 708 along the length of the cable by a bonding material. Thus, anedge insulation structure 710 is formed where the outmost layer,typically a dielectric material, of the cable 700 covers the edge.Optionally, in some implementations, the second portion 712 of thesecond layer 709 and the second portion 716 of the first layer 708 canbe bonded by a bonding material 722. In some cases, the bonding material722 can be used in the cable construction and the bonding material 722is extruded from the cable.

FIGS. 7O and 7P illustrate two other embodiments of constructing an edgeinsulation structure by folding. Referring to FIGS. 7O and 7P, anelectrical cable 700 can include a first layer 708 and a second layer709. The electrical cable 700 typically has a dielectric outmost layer.Both the first layer 708 and the second layer 709 can be folded towardthe other layer respectively. The second layer 709 can be folded alongthe length of the cable toward the first layer 708, and the folddefining a first portion 711 of the second layer 709 and a secondportion 712 of the second layer 709. The second portion 712 of thesecond layer 709 may include the longitudinal edge of the second layer709. The second portion 712 of the second layer can be bonded to thefirst portion 711 of the second layer along the length of the cable by abonding material. Optionally, the first layer 708 can be folded alongthe length of the cable toward the second layer 709, and the folddefining a first portion 717 of the first layer 708 and a second portion716 of the first layer 708. The second portion 716 of the first layer708 may include the longitudinal edge of the first layer 708. The secondportion 716 of the first layer 708 can be bonded to the first portion717 of the first layer 708 along the length of the cable by a bondingmaterial. Thus, an edge insulation structure 710 is formed where theoutmost layer, typically a dielectric material, of the cable 700 coversthe edge.

FIG. 7O illustrates an exemplary implementation where the first layer708 is trimmed shorter than the second layer 709. In this embodiment,the second portion 716 of the first layer 708 can be bonded to the firstportion 711 of the second layer 709 to form an edge insulation structure710. FIG. 7P illustrates an exemplary implementation where the secondlayer 709 is trimmed shorter than the first layer 708 along thelengthwise of the cable 700. In this embodiment, the second portion 712of the second layer 709 can be bonded to the first portion 717 of thefirst layer 708 to form an edge insulation structure 710.

Hot Melt Die Device

In some embodiments, edge beads may be constructed by a die assembly, asillustrated in FIG. 8. A die assembly may also be used to apply materialto an edge of a film. In some embodiments, a die assembly can include adie that is configured to dispense a material through a die tip. In someimplementations, an edge of a film is positioned proximate the die tip,where the die dispenses the material to at least one of a top and bottomsurfaces of the film proximate and along the edge of the film. Thus, thedispensed material can form a coating region on the film, where thecoating region is limited to near the edge of the film.

FIG. 8 illustrates an exemplary embodiment of a die assembly 800. Insome embodiments, the die assembly 800 has a die tip 810 as a wholemachine part. In some embodiment, the die tip 810 can include an upperdie lip 820 and a lower die lip 840. Optionally, the die tip 810 caninclude a die insert 830 and a mechanical means 850 to assemble the dieinsert 830 with the die lips 820 and 840. In some implementations,optionally, a die feeding channel 860 can be inserted into the die tip810 to allow materials to flow along a direction 870. A die assembly isconfigured to dispense material through the die tip 810. In someimplementations, different die inserts 830 may be assembled into the dietip 810, which have different mechanical structures suitable todifferent film configurations and different edge configurations. In someimplementations, an edge of a film can be disposed proximate, and thedie assembly 800 dispenses a material to at least one of a top andbottom surfaces of the film proximate and along the edge of the film.The dispensed material forms a coated region on the film, where thecoated region is limited to near the edge of the film. In some otherimplementations, a longitudinal edge of an electrical cable can bepositioned proximate the die tip 810. The die assembly 800 can dispensean insulating material to at least one of a top and bottom surfaces ofthe film proximate and along the edge of the electrical cable. Theinsulating material is then allowed to flow over the longitudinal edgeof the electrical cable. In some cases, the insulating material can beprevented a further flow by solidifying, curing, or other approaches.

FIG. 9A illustrates a perspective view of an embodiment of a dieassembly 900 and a film 920. FIG. 9B illustrates a side view of theembodiment of the die assembly 900 illustrated in FIG. 9A. The dieassembly 900 can include a die manifold 905 and a die tip 907. The dietip 907 can include two die lips 910: an upper die lip and a lower dielip. Optionally, the die assembly 900 may have a guiding insert 930 tokeep the cable in the center position. In an exemplary embodiment, thedie lips 910 can have a groove in the surface to guide the flow of edgeinsulating material 940. The edge insulating material 940 is flowing inthe direction 950. In a particular embodiment, at least one of the twodie lips 910 having a groove allows the edge insulating material 940 toflow through the groove onto at least one of the top and bottom surfacesof the film. In some implementations, the edge insulating material 940can flow from at least one of the top and bottom surfaces of the film tocover the edge of the film 920, also illustrated in FIG. 9C.

FIG. 10A illustrates a perspective view of another embodiment of a dietip 1000 and FIG. 10B illustrates a side view of the embodiment of thedie tip 1000 illustrated in FIG. 10A. The die tip 1000 can include afirst die lip 1010 and a second die lip 1020 facing the first die lip1010. In some embodiments, the first die lip 1010 and the second die lip1020 can have a triangle cross-section at the dispensing portion. Insome embodiments, a film 1030 can be disposed between the first die lip1010 and the second die lip 1020. Edge insulating material 1040 can bedispensed from at least one of the first die lip 1010 and the second dielip 1020. In a particular embodiment that is important to providesufficiently strong bonding of the edge insulating material 1040, theedge insulating material 1040 can be dispensed to the upper surfaceand/or the lower surface of the film 1030 and flow in the direction of1050 to seal the edge of the film 1030.

In some embodiments, a die tip can include a dispensing portion allowingmaterial to exit from the die tip. The dispensing portion may be indifferent shapes in cross section, for example, triangle, round, or thelike. In some implementations, the dispensing portion can include adispensing opening where material can exit from the die tip. Thedispensing opening can be machined to a specific dimension.Alternatively, the dispensing opening can use shims to be able to varythe gap opening and change the material flow rate such that thethickness of the edge insulation structure can be adjusted to a desiredthickness.

FIG. 11A illustrates a close-up perspective view of an embodiment of adie tip dispensing portion 1100 a. The die tip dispensing portion 1100 ahas a dispensing portion with a triangle shaped cross section. The dietip dispensing portion 1100 a has a dispensing opening 1110 a. FIG. 11Billustrates a close-up perspective view of another embodiment of a dietip dispensing portion 1100 b. The die tip dispensing portion 1100 b hasa dispensing portion with a round shaped cross section. The die tipdispensing portion 1100 b has a dispensing opening 1110 b.

A dispensing opening may have various shapes and positions at the dietip. For example, a dispensing opening can be a round opening, a slottedopening, or the like. FIG. 12A illustrates a die lip open view of anembodiment of a die tip 1200. FIG. 12B illustrates a side view of theembodiment of the die tip 1200 illustrated in FIG. 12A. The die tip 1200has two die lips 1210 facing each other, two die inserts 1230, and twodispensing openings 1220. In some configurations, one die lip may have adispensing opening 1220 and the other die lip may not have a dispensingopening. The dispensing opening 1220 can be generally round andpositioned toward the back edge of the die lip 1210.

FIG. 13A illustrates a die lip open view of another embodiment of a dietip 1300. FIG. 13B illustrates a side view of the embodiment of the dietip 1300 illustrated in FIG. 13A. The die tip 1300 has two die lips 1310facing each other, two die inserts 1330, and two dispensing openings1320. In some configurations, one die lip may have a dispensing opening1320 and the other die lip may not have a dispensing opening. Thedispensing opening 1320 can be generally round and positioned at thecenter of the die lip 1310.

FIG. 14A illustrates a die lip open view of yet another embodiment of adie tip 1400. FIG. 14B illustrates a side view of the embodiment of thedie tip 1400 illustrated in FIG. 14A. The die tip 1400 has two die lips1410 facing each other, two die inserts 1430, and two dispensing ports1420. In some configurations, one die lip may have a dispensing port1420 and the other die lip may not have a dispensing opening. Thedispensing port 1420 can be a slotted opening. In a particularembodiment, the dispensing opening can be generally perpendicular to theflowing direction of dispensed materials.

A first embodiment is an edge insulated electrical cable comprising anelectrical cable having a conductive material disposed near a locationat a longitudinal edge of the electrical cable and susceptible to makingelectrical contact at the location; and an insulating material bonded tothe electrical cable at the location.

A second embodiment is the edge insulated electrical cable of the firstembodiment, wherein the insulating material comprises material used inthe electrical cable's construction.

A third embodiment is the edge insulated electrical cable of the firstembodiment, wherein the insulating material comprises a thermoplasticmaterial.

A fourth embodiment is the edge insulated electrical cable of the firstembodiment, wherein the insulating material comprises a curablecompound.

A fifth embodiment is the edge insulated electrical cable of the firstembodiment, further comprising a conductive material covering the edgeat the location and the insulating material covering the conductivematerial.

A sixth embodiment is an electrical cable comprising a conductorextending lengthwise along the cable; and a reservoir extendinglengthwise along the cable at a first lateral location in the cable,wherein the reservoir contains a dielectric material adapted to betransferred to a different second lateral location in the cable.

A seventh embodiment is the electrical cable of the sixth embodiment,wherein the second lateral location is at a longitudinal edge of thecable.

An eighth embodiment is the electrical cable of the sixth embodiment,further comprising an edge insulation structure formed at the reservoir,wherein the reservoir comprises an insulation layer, wherein the edgeinsulation structured is formed partially by a portion of the insulationlayer of the reservoir.

A ninth embodiment is an edge insulated electrical cable comprising anelectrical cable having a conductive material disposed near alongitudinal edge and susceptible to making electrical contact at theedge, wherein the cable is folded along the length of the cable, thefold defining a first portion facing a second portion, the secondportion comprising the longitudinal edge of the cable, and a bondingmaterial bonding the second portion to the first portion along thelength of the cable.

A tenth embodiment is the edge insulated electrical cable of the ninthembodiment, wherein the bonding material covers the longitudinal edge.

An eleventh embodiment is the edge insulated electrical cable of theninth embodiment, wherein the electrical cable comprises a filmcomprising the insulating material.

A twelfth embodiment is an edge insulated electrical cable comprising anelectrical cable having a first layer and a second layer, the secondlayer having a conductive material disposed near a longitudinal edge ofthe second layer and susceptible to making electrical contact at theedge, wherein the second layer is folded along the length of the cabletoward the first layer, the fold defining a first portion of the secondlayer facing a second portion of the second layer, the second portion ofthe second layer comprising the longitudinal edge of the second layer,and a bonding material bonding the second portion of the second layer tothe first portion of the second layer along the length of the cable.

A thirteenth embodiment is the edge insulated electrical cable of thetwelfth embodiment, wherein the bonding material comprises material usedin the electrical cable's construction.

A fourteenth embodiment is a method of applying an insulating materialto a longitudinal edge of an electrical cable, comprising dispensing theinsulating material to at least one of a top and bottom surfaces of theelectrical cable proximate and along the longitudinal edge; allowing theinsulating material to flow over the longitudinal edge; and preventing afurther flow of the insulating material.

A fifteenth embodiment is the method of the fourteenth embodiment,wherein the preventing step comprises solidifying the insulationmaterial.

A sixteenth embodiment is the method of the fifteenth embodiment,wherein the preventing step comprises curing the insulation material.

A seventeenth embodiment is an apparatus for film edge coating,comprising a die assembly configured to dispense a material through adie tip, and an edge of a film positioned proximate the die tip, whereinthe die assembly dispenses the material to at least one of a top andbottom surfaces of the film proximate and along the edge of the film,the dispensed material forming a coated region on the film, the coatedregion being limited to near the edge of the film.

An eighteenth embodiment is the apparatus of the seventeenth embodiment,wherein the film is an electrical cable.

A nineteenth embodiment is the apparatus of the seventeenth embodiment,wherein the die tip includes a dispensing opening allowing the materialto exit from the die tip.

The present invention should not be considered limited to the particularexamples and embodiments described above, as such embodiments aredescribed in detail to facilitate explanation of various aspects of theinvention. Rather the present invention should be understood to coverall aspects of the invention, including various modifications,equivalent processes, and alternative devices falling within the spiritand scope of the invention as defined by the appended claims.

What is claimed is:
 1. An edge insulated electrical cable comprising: anelectrical cable having a conductive material disposed near a locationat a longitudinal edge of the electrical cable and susceptible to makingelectrical contact at the location; and an insulating material bonded tothe electrical cable at the location.
 2. An edge insulated electricalcable according to claim 1, wherein the insulating material comprisesmaterial used in the electrical cable's construction.
 3. An edgeinsulated electrical cable according to claim 1, wherein the insulatingmaterial comprises a thermoplastic material.
 4. An edge insulatedelectrical cable according to claim 1, wherein the insulating materialcomprises a curable compound.
 5. An edge insulated electrical cableaccording to claim 1, further comprising: a conductive material coveringthe edge at the location and the insulating material covering theconductive material.
 6. An electrical cable comprising: a conductorextending lengthwise along the cable; and a reservoir extendinglengthwise along the cable at a first lateral location in the cable,wherein the reservoir contains a dielectric material adapted to betransferred to a different second lateral location in the cable.
 7. Theelectrical cable of claim 6, wherein the second lateral location is at alongitudinal edge of the cable.
 8. The electrical cable of claim 6,further comprising: an edge insulation structure formed at thereservoir, wherein the reservoir comprises an insulation layer, whereinthe edge insulation structured is formed partially by a portion of theinsulation layer of the reservoir.
 9. An edge insulated electrical cablecomprising: an electrical cable having a conductive material disposednear a longitudinal edge and susceptible to making electrical contact atthe edge, wherein the cable is folded along the length of the cable, thefold defining a first portion facing a second portion, the secondportion comprising the longitudinal edge of the cable, and a bondingmaterial bonding the second portion to the first portion along thelength of the cable.
 10. An edge insulated electrical cable according toclaim 9, wherein the bonding material covers the longitudinal edge. 11.An edge insulated electrical cable according to claim 9, wherein theelectrical cable comprises a film comprising the insulating material.12. An edge insulated electrical cable comprising: an electrical cablehaving a first layer and a second layer, the second layer having aconductive material disposed near a longitudinal edge of the secondlayer and susceptible to making electrical contact at the edge, whereinthe second layer is folded along the length of the cable toward thefirst layer, the fold defining a first portion of the second layerfacing a second portion of the second layer, the second portion of thesecond layer comprising the longitudinal edge of the second layer, and abonding material bonding the second portion of the second layer to thefirst portion of the second layer along the length of the cable.
 13. Anedge insulated electrical cable according to claim 12, wherein thebonding material comprises material used in the electrical cable'sconstruction.
 14. A method of applying an insulating material to alongitudinal edge of an electrical cable, comprising: dispensing theinsulating material to at least one of a top and bottom surfaces of theelectrical cable proximate and along the longitudinal edge; allowing theinsulating material to flow over the longitudinal edge; and preventing afurther flow of the insulating material.
 15. The method of claim 14,wherein the preventing step comprises solidifying the insulationmaterial.
 16. The method of claim 15, wherein the preventing stepcomprises curing the insulation material.
 17. An apparatus for film edgecoating, comprising: a die assembly configured to dispense a materialthrough a die tip, and an edge of a film positioned proximate the dietip, wherein the die assembly dispenses the material to at least one ofa top and bottom surfaces of the film proximate and along the edge ofthe film, the dispensed material forming a coated region on the film,the coated region being limited to near the edge of the film.
 18. Anapparatus according to claim 17, wherein the film is an electricalcable.
 19. An apparatus according to claim 17, wherein the die tipincludes a dispensing opening allowing the material to exit from the dietip.